Jungheinrich DFG 435 Operating Instructions Manual
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Jungheinrich DFG 435 Operating Instructions Manual

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DFG/TFG 316-435
Operating instructions
51167624
08.11
J UNGHEINRICH
ö
11.09 -
G
DFG 316
DFG 320
DFG 425
DFG 430
DFG 435
TFG 316
TFG 320
TFG 425
TFG 430
TFG 435

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  • Page 1 DFG/TFG 316-435 11.09 - Operating instructions 51167624 DFG 316 08.11 DFG 320 DFG 425 DFG 430 DFG 435 TFG 316 TFG 320 TFG 425 TFG 430 TFG 435 ö J UNGHEINRICH...
  • Page 3 Declaration of Conformity Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union Type Option Serial no. Year of manufacture DFG 316 DFG 320 DFG 425 DFG 430 DFG 435 TFG 316 TFG 320 TFG 425...
  • Page 5 Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck should therefore be assumed from the present operating instructions.
  • Page 6 Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...

  • Page 7: Table Of Contents

    Table of Contents Correct Use and Application ........... General....................Correct application................... Approved application conditions .............. Proprietor responsibilities ................ Adding attachments and/or accessories..........Truck Description ..............Application ....................Truck models and rated capacity............. Assemblies and Functional Description........... Assembly Overview ................. Functional Description ................Technical Specifications ................
  • Page 8 Fuelling the Truck..............General....................Safety regulations for handling diesel fuel and LPG........ LPG system relief valve................Adding diesel ................... Fuelling ....................Fuelling with fuel containers ..............LPG containers..................LPG bottles....................Liquid gas tank ..................Fuel level indicator................... Display unit ....................Level indicator for LPG bottles (o) ............
  • Page 9 Rockinger coupling with hand lever or remote control......105 6.10 Camera system ..................106 6.11 Optional equipment for working in areas with heavy accumulation of dust 107 6.12 Roof window wiper .................. 107 6.13 Tilt angle display..................108 6.14 Speed reduction ..................108 6.15 Reversing Block..................

  • Page 11: A Correct Use And Application

    A Correct Use and Application General The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units. It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the industrial truck or property.

  • Page 12: Approved Application Conditions

    Approved application conditions DANGER! Do not exceed the permissible surface and spot load limits on the travel routes. At blind spots get a second person to assist. The driver must ensure that the loading dock / ramp cannot move or come loose during loading / unloading.

  • Page 13: Proprietor Responsibilities

    Proprietor responsibilities For the purposes of the present operating instructions the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.

  • Page 15: B Truck Description

    B Truck Description Application The DFG/TFG 316-435 is a four-wheel IC motor sit-down forklift truck. The DFG series are diesel engine trucks, while the TFG series are fitted with a petrol engine for LPG operation. The DFG/TFG 316-435 is a cantilever counterbalanced truck which can lift, transport and deposit loads using the load handler attached in front.

  • Page 16: Assemblies And Functional Description

    Assemblies and Functional Description Assembly Overview Item Description Item Description 1 t Overhead guard 9 t Lift mechanism control 2 t Driver's seat 10 t Engine Cover 3 t Steering wheel 11 t Steer axle 4 t Control / display unit 12 t Trailer coupling 5 t Mast 13 t Counterweight...

  • Page 17: Functional Description

    Functional Description Chassis The chassis, in conjunction with the counterweight, forms the supporting base structure of the truck. It is used to support the main components. The hydraulic oil reservoir is integrated on the right-hand side and the fuel tank for the DFG series is on the left side in the chassis.
  • Page 18 Drive system A power shift gear with radiator and torque converter transfers the force to the drive axle (8). The travel direction switch on the left hydraulic control lever regulates forward/reverse travel and the neutral position. Brakes The brake pedal actuates two drum brakes which are applied to the drive wheels. An additional slow travel / brake pedal facilitates creep speed applications.

  • Page 19: Technical Specifications

    Technical Specifications All technical details refer to standard trucks. Values indicated with *) may vary, depending on the types of equipment used (e.g. mast, cabin, tyres etc.). Technical data specified in accordance with VDI 2198. Technical modifications and additions reserved. Performance data DFG 316/320 Description...
  • Page 20 TFG 316/320 Description TFG 316 TFG 320 Capacity 1600 2000 where C = 500 mm) Load centre distance Travel speed* with / 18.7/19.5 18.5/19.3 km/h without load Lift speed, with / without 0.61/0.63 0.60/0.63 load Lowering speed with / 0.55/0.49 0.57/0.49 without load Gradeability...
  • Page 21 DFG 425-435 Description DFG 425 DFG 430 DFG 435 Capacity 2500 3000 3500 (where C = 500 mm) Load centre distance Travel speed* with / 17/19 18/19 18/19 km/h without load Lift speed, with / without 0.53/0.60 0.53/0.60 0.49/0.54 load Lowering speed with / 0.55/0.45...

  • Page 22: Dimensions

    Dimensions DFG/TFG 316/320 Description DFG/TFG 316 DFG/TFG 320 a/2 Safety distance Mast height retracted* 2185 2185 Free lift* Lift* 3300 3300 Mast height extended* 3920 3920 Overhead guard height* 2145 2145 Seat height* 1049 1049 Coupling height Mast tilt, fwd.* °...
  • Page 23 DFG / TFG 425-435 Description DFG/TFG 425 DFG/TFG 430 DFG/TFG 435 a/2 Safety distance Mast height retracted* 2280 2280 2215 Free lift* Lift* 3300 3300 2900 Mast height extended* 3910 3910 3670 Overhead guard height* 2220 2250 2250 Seat height* 1082 1112 1112...
  • Page 24 α β...

  • Page 25: Weights

    3940/530 4600/680 3930/520 4580/670 rear* *) The data listed in the table corresponds to the standard version. DFG 425/430/435 DFG 425 DFG 430 DFG 435 Truck weight* 4290 4730 5028 Axle load w.o. load front / 2050/2240 2078/2719 2028/3000 rear*...

  • Page 26: Mast Versions

    Mast versions All dimensions in mm DFG/TFG 316/320 Mast table Mast VDI 3596 Free lift Height retracted Height Lift h3 weight Description extended h4 (kg) 2900 1985 3520 3100 2085 3720 3300 2185 3920 3600 2335 4220 3800 2435 4420 4000 2535 4620...
  • Page 27 DFG/TFG 425/430 Mast table VDI 3596 Lift h Free lift h Retracted Extended Mast Description height h height h weight (kg) 4 425/430 425/430 2900 2115 3510/3670 3100 2215 3710/3870 3300 2315 3910/4070 3500 2415 4110/4270 3700 2515 4310/4470 4000 2665 4610/4770 4300...
  • Page 28 DFG/TFG 435 Mast table VDI 3596 Lift h Free lift h Retracted Extended Mast Description height h height h weight (kg) 2900 2228 3683 3300 2428 4083 3800 2678 4583 4300 2978 5083 4800 3228 5583 5000 3328 5783 4200 1330 2093 4963...

  • Page 29: Tyre Type

    Tyre type NOTE When replacing tyres/rims fitted at the factory, always use original spare parts or tyres approved by the manufacturer. Otherwise the manufacturer's specification cannot be guaranteed. If you have any queries please contact the manufacturer's customer service department. DFG/TFG 316/320 Description DFG / TFG...

  • Page 30: Engine Data

    Rated speed (without load) 2700 2700 Engine output Fuel consumption l/h [kg/h] 60 VDI duty cycles/h DFG 425-435 Description DFG 425 DFG 430 DFG 435 Cylinder/cubic capacity 4/3331 4/3331 4/3331 cm³ Idle speed Rated speed (without load) 2350 2350 2350...

  • Page 31: Norms

    EN norms Noise emission level – DFG/TFG 425/430: 79 dB (A)* – DFG/TFG 435: 79 dB(A)* *+/- 3 dB(A) depending on the truck's equipment in accordance with 12053 as harmonised with ISO 4871. The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle.

  • Page 32: Conditions Of Use

    Conditions of use Ambient temperature – operating at -20 to 40°C Special equipment and authorisation are required if the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations. Electrical requirements The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - Electrical Requirements", provided the truck is used according to its purpose.

  • Page 33: Identification Points And Data Plates

    Identification points and data plates Warnings and notices such as capacity charts, strap points and data plates must be legible at all times. Replace if necessary.
  • Page 34 Item Description Wear seat belt notice Strap points for crane lifting Do not travel with raised load or mast tilted forward with a raised load Capacity Capacity with attachment Fuel Tipover hazard Read operating instructions Jump start connection Truck data plate; under the engine cover (not shown) Do not stand on load handler / Do not stand under load handler / Risk of trapping when mast extended Noise level...

  • Page 35: Data Plate

    Data plate Item Description Item Description Type Year of manufacture Serial number Load centre (mm) Rated capacity (kg) Output Output Manufacturer Net weight in kg Manufacturer’s logo Option For queries regarding the truck or ordering spare parts always quote the truck serial number (34).

  • Page 36: Truck Capacity Plate

    Truck capacity plate CAUTION! Accident risk from fork replacement If you replace the forks with ones that differ from the originals, the capacity will change. When replacing the forks you must attach an additional capacity plate to the truck. Trucks supplied without forks are given a capacity plate for standard forks (length: 1150 mm).

  • Page 37: Attachment Capacity Plate

    Attachment capacity plate The attachment capacity plate is next to the truck's capacity plate and gives the truck's capacity Q (in kg) in conjunction with the respective attachment. The serial number for the attachment indicated on the capacity plate must match the data plate of the attachment.

  • Page 39: C Transport And Commissioning

    C Transport and Commissioning Transport Transport can be carried out in two different ways, depending on the height of the mast and the local conditions. – Vertically, with the mast assembled (for low heights) – Vertically, with the mast dismantled (for large heights), all mechanical connections and hydraulic lines between the basic truck and the mast separated.

  • Page 40: Lifting The Truck By Crane

    Lifting the truck by crane CAUTION! The mast can get damaged Loading by crane is only intended for the initial transport before the truck is used for the first time. Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 DANGER! Crane slings can tear, resulting in accidents...

  • Page 41: Loading With Another Industrial Truck

    Loading with another industrial truck WARNING! The truck can be damaged The truck to be loaded can get damaged when loading with another industrial truck. Only trained specialist personnel should load the truck. Use only trucks with sufficient capacity for loading. Only for loading and unloading.

  • Page 42: Securing The Truck During Transport

    Securing the truck during transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case correct measurements must be made and appropriate safety measures adopted.

  • Page 43: Using The Truck For The First Time

    Using the Truck for the First Time Safety Instructions for Assembly and Commissioning WARNING! Accident risk from incorrect assembly The assembly of the truck at the application site, commissioning and driver training must only be performed by the manufacturer's customer service representatives who have been specially trained for these tasks.

  • Page 45: D Fuelling The Truck

    D Fuelling the Truck General Safety regulations for handling diesel fuel and LPG WARNING! An unsecured truck can cause accidents The truck can suddenly start to move. Before filling up or replacing the LPG bottle, park the truck securely, Siehe “Parking the truck securely”...
  • Page 46 NOTE Fuel can cause environmental damage Bind any spilled diesel fuel with suitable methods. Then dispose of the diesel and fuel filter in accordance with environmental regulations. Fuel filling and LPG bottle replacement personnel Personnel filling the trucks or replacing LPG bottles must have sufficient knowledge of the nature of fuels to ensure safe operation.

  • Page 47: Lpg System Relief Valve

    LPG system relief valve LPG powered trucks are fitted with a relief valve. This is located on the rear cover next to the gas bottle. – In the event of a fault the pressure in the gas system is restricted to a maximum level.

  • Page 48: Adding Diesel

    Adding diesel CAUTION! Air in the fuel system will result in malfunctions. Never allow the fuel tank to run dry. Fuelling WARNING! Diesel fuel can be hazardous Diesel fuel can cause irritation if it comes into contact with the skin. Rinse any affected areas thoroughly.

  • Page 49: Fuelling With Fuel Containers

    Fuelling with fuel containers Procedure • Unscrew the tank cap (50) and open the fuel container. • Fit the outlet pipe onto the fuel container. • Insert the outlet pipe into the open tank filler neck. • Make sure the fuel container and outlet pipe are connected tightly to each other.

  • Page 50: Lpg Containers

    LPG containers Only use liquid gas that complies with DIN 51622 or comparable national regulations. LPG bottles DANGER! Risk of explosion The LPG bottle must only be replaced at designated areas by trained and authorised personnel. CAUTION! Using unsuitable LPG bottles can cause accidents. Use only approved LPG bottles.
  • Page 51 Remove the LPG bottle CAUTION! The connection has a left thread Procedure • Unscrew the union nut (52) while holding against the handle (54). • Remove the hose (55) and immediately screw the valve cap onto the empty LPG bottle. •...
  • Page 52 3.1.2 Operating with two LPG bottles WARNING! Visibility is restricted when the truck reverses. When using two LPG bottles the truck must be fitted with a functional camera system for reversing. External mirrors must also be fitted on either side of the truck. Operating the twin bottle system NOTE Use the additional valve (60) on the...

  • Page 53: Liquid Gas Tank

    Liquid gas tank Refillable liquid gas tanks contain a dispensing valve (66), a filling stop valve (64), a relief valve (65) and a display (62). Filling refillable liquid gas tanks (optional equipment). Requirements – Note guidelines regulations concerning the filling of LPG bottles on the LPG pump.

  • Page 54: Fuel Level Indicator

    Fuel level indicator Display unit The level indicator (68) shows the capacity of the tank (only for DFG). If the indicator (68) reaches the red zone, fill the tank. This is also displayed by the spare indicator (67). Level indicator for LPG bottles (o) When the level indicator for LPG bottles (69) is lit (o), this indicates that the LPG bottle is empty.

  • Page 55: E Operation

    E Operation Safety Regulations for the Operation of the Forklift Truck Driver authorisation The truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.
  • Page 56 Hazardous area WARNING! Risk of accidents / injury in the hazardous area of the truck The hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself.

  • Page 57: Displays And Controls

    Displays and Controls...
  • Page 58 Item Control / Function Display t Selects travel direction / neutral position Direction switch t Activates an audible warning. Horn Slow travel / brake pedal t 1. zone: controls slow travel. 2. zone: applies service brake. t Applies / releases parking brake Parking brake lever t Steering the Industrial truck.

  • Page 59: Control Panel With Display Unit

    Control panel with display unit The control panel display unit shows the operating data, the battery charge, the service hours and error details and information. Pictograms in the left top section of the control panel act as warning indicators. 91 92 93 Item Control / Function...
  • Page 60 Item Control / Function Display t When lit, indicates the brake fluid level Brake fluid indicator is too low. t Parking brake activated Parking brake warning indicator – Truck operational, parking brake applied t Lights up to indicate that the diesel Diesel filter indicator filter is clogged.
  • Page 61 2.1.1 Instrument panel switches (o) Display Function Front work lights Switches front work lights on and off. Rear work lights Switches rear work lights on and off. Beacon Switches the beacon on and off. Rear windscreen Switches rear windscreen wiper on and wiper off.

  • Page 62: Preparing The Truck For Operation

    Preparing the Truck for Operation Checks and operations to be performed before starting daily operation WARNING! Damage and other truck or attachment (special equipment) defects can result in accidents. If damage or other truck or attachment (special equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

  • Page 63: Entry And Exit

    Entry and exit Procedure • Open the cab door (o) • To enter and exit the cab, hold onto the handle (97). An additional step is provided for the driver position extension (o) Trucks with reduced headroom X (o) WARNING! An unsuitable workplace can damage your health Failure to observe the recommended...

  • Page 64: Setting Up The Operator Position

    Setting up the operator position WARNING! Accident risk Do not adjust the driver’s seat while travelling. Procedure • Before starting to travel, adjust the driver’s seat, steering column and armrest (if necessary) so that all the controls are within reach and can be applied without having to strain.
  • Page 65 Adjusting the driver's weight NOTE To achieve optimal seat cushioning the driver’s seat must be set to the driver’s weight. Set the driver's weight when the seat is occupied. Procedure • Fold out the weight adjustment lever (98) as far as it will go in the arrow direction •...
  • Page 66 Driver’s seat with pneumatic weight adjustment (MSG 75) ( Procedure • Pull the weight adjustment lever (98) up to set the seat to a higher weight. • Push the weight adjustment lever (98) down to set the seat to a lower weight. The driver's weight is correct when the arrow is in the middle of the display window (99).
  • Page 67 3.4.2 Adjusting the steering wheel / steering column CAUTION! Do not adjust the steering wheel while travelling Individual steering wheel position The tilt of the steering wheel can adjusted to suit the operator. Procedure • Pull the steering wheel adjusting lever (103) in the direction of the arrow (105).

  • Page 68: Seat Belt

    Seat Belt DANGER! Travelling without a seat belt increases the risk of injury. If the seat belt is not worn or is modified, personal injury can result. Always put on the seat belt before starting the industrial truck. Do not modify the seat belt. Damaged or non-operational seat belts must be replaced by trained personnel.

  • Page 69: Industrial Truck Operation

    Industrial Truck Operation Safety regulations for truck operation Travel routes and work areas Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose. The truck must only be operated in work areas with sufficient lighting to avoid danger to personnel and materials.
  • Page 70 Prevent liquid loads from sloshing out. Inflammable liquids (e.g. fused metal etc.) may only be transported with suitable auxiliary equipment. Contact your authorized Jungheinrich customer adviser. For safety instructions on the nature of loads to be carried with attachments,(see "Lifting, transporting and depositing loads"...

  • Page 71: Preparing The Truck For Operation

    Preparing the truck for operation Before starting the truck The truck should only be operated from the driver’s seat. Do not run up the engine in idle. The engine soon reaches operating temperature at a moderate charge and when the speed alternates. Only fully charge the engine once it has reached operating temperature.
  • Page 72 4.2.1 Starting procedure for the DFG Procedure • • Insert the key in the key switch (76). Set key switch to “I”. • The pre-heat indicator lamp (91) lights up and goes out automatically as soon as the required pre-heat time (approx. 4 seconds) has been reached.
  • Page 73 4.2.2 Starting procedure for the TFG DANGER! Risk of escaping liquid gas if the truck does not start Note the safety regulations governing the handling of liquid gas ((see "Safety regulations for handling diesel fuel and LPG" on page 45)) Close the gas bottle shut-off valve.

  • Page 74: Parking The Truck Securely

    Parking the truck securely DANGER! Risk of explosion LPG trucks may only be parked in ground level rooms or higher and providing they are adequately ventilated. They must not be parked near to cellar doors and entry points, hollows, drains, drain inlets or other recesses below the parked truck. WARNING! An unsecured truck can cause accidents Parking the truck on an incline, without the brakes applied or with a raised load / load...

  • Page 75: Emergency Disconnect

    Emergency Disconnect Procedure • Move the key switch to the O position. • Open the engine panel and remove the quick release lock from the battery pool. This disconnects the battery from the on-board supply network and switches off all electrical functions.

  • Page 76: Travel

    Travel WARNING! Improper travel can result in accidents Do not get up from the driver’s seat during travel. Do not drive the truck unless your are wearing a seat belt and the panels and doors are properly locked. Make sure that the travel area is clear. Adapt the travel speed to the conditions of the route, the work area and the load.

  • Page 77: Steering

    Slow travel / brake pedal Requirements – Truck ready operation, (see "Preparing the truck for operation" on page 71). Procedure • Apply the slow travel / brake pedal (72) sensitively. The Industrial truck moves slowly in the selected travel direction and allows for excellent shunting in confined areas.

  • Page 78: Brakes

    Brakes WARNING! Accident risk The brake pattern of the truck depends largely on the ground conditions. The driver must be aware of travel route conditions and them into account when braking. Brake with care to prevent the load from slipping. Allow for increased braking distance when travelling with an attached load.
  • Page 79 4.7.2 Parking brake DANGER! Accident risk The parking brake will hold the truck with maximum load on a clean ground surface, on inclines of up to 15%. Do not park and abandon the truck on an incline. Applying the parking brake during travel will cause the truck to brake to a standstill. This may cause the load to slide off the forks tines.

  • Page 80: Adjusting The Forks

    Adjusting the forks WARNING! Trapping hazard There is a trapping hazard when you perform this operation. Wear work gloves and safety shoes. WARNING! Unsecured and incorrectly adjusted forks can cause accidents Before adjusting the forks make sure the retaining bolts (96) are fitted. Adjust the forks so that both forks are equidistant from the outside edge of the fork carriage.

  • Page 81: Replacing The Forks

    Replacing the forks WARNING! Unsecured forks can cause injury You can injure your legs when replacing the forks. Never pull the forks towards your body. Always push the forks away from your body. Secure heavy forks with lifting slings and a crane before pushing them down from the fork carriage.

  • Page 82: Lifting, Transporting And Depositing Loads

    4.10 Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents Before lifting a load unit the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity. Instruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous area.
  • Page 83 NOTE Loads must not be deposited on travel or escape routes, in front of safety mechanisms or operating equipment that must be accessible at all times. Transporting load units Requirements – Load unit correctly lifted. – Load handler lowered for transport (approx. 150 - 200 mm above the ground). –...

  • Page 84: Operating The Lift Mechanism And Integrated Attachments

    4.11 Operating the lift mechanism and integrated attachments WARNING! Accident risk when operating the lifting device and integrated attachments Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the truck movement, the load handler, attachments etc.
  • Page 85 Controlling the speed of the lifting device Moving the lever and changing the engine speed governs the operating speed of the hydraulic cylinders. When the levers (115, 114) are released they automatically revert to neutral and the lifting device remains in the position it has reached.
  • Page 86 4.11.1 Operating the lift mechanism with the SOLO PILOT Lifting and lowering Requirements – To prepare the truck for operation, (see "Preparing the truck for operation" on page 71) Procedure • Pull the Solo-Pilot lever (116) in direction H to raise the load.
  • Page 87 Positioning the integrated sideshift (option) Requirements – To prepare the truck for operation, (see "Preparing the truck for operation" on page 71) Procedure • Pull the Solo-Pilot lever (118) in direction R to move the load handler to the right (from the driver’s viewpoint).
  • Page 88 Positioning the forks with an integrated fork adjuster (option) CAUTION! Do not use the fork adjuster to clamp loads. Requirements – Truck prepared for operation, (see "Preparing the truck for operation" on page 71). Procedure • Press the toggle switch (119) and at the same time pull the Solo Pilot (120) in direction Z: the forks will move towards each other.

  • Page 89: Safety Instructions For Operating Additional Attachments

    4.12 Safety instructions for operating additional attachments Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to operate attachments. The auxiliary hydraulics are indicated with ZH1, ZH2 and ZH3. Auxiliary hydraulic functions for exchangeable equipment are fitted with replacement couplings on the fork carriage.
  • Page 90 Safety instructions for sideshifter and fork adjuster attachments WARNING! When using multi fork adjusters (multi pallet clamps), restricted visibility and reduced lateral tilt resistance can result in accidents. Adapt the travel speeds to the visibility and load. Make sure you have enough visibility when reversing. Safety instructions for clamping attachments (e.g.
  • Page 91 Safety instructions for attachments when transporting suspended loads WARNING! Swinging loads and a reduced residual capacity can result in accidents Adapt the travel speed to the load, less than walking pace. Secure swinging loads for example with lifting slings. Reduce the residual capacity and have it certified by a expert. Safety instructions for using loading buckets as attachments WARNING! Greater mast loading can cause accidents.

  • Page 92: Operating Additional Attachments For The Solo-Pilot

    4.13 Operating additional attachments for the SOLO-PILOT WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. Mark the controls with symbols that indicate their function. Specify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
  • Page 93 4.13.2 Solo Pilot with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (118, 120, 119) is assigned the function of the attachment. Levers that are not required are void. For connections (see "Fitting additional attachments"...

  • Page 94: Fitting Additional Attachments

    4.14 Fitting additional attachments WARNING! Incorrectly connected attachments can cause accidents. Attachments with incorrectly connected hydraulic attachments can result in accidents. Attachments must only be assembled and commissioned by trained, specialist personnel. Note the attachment manufacturer’s operating instructions. Before commissioning, check the fasteners are positioned correctly and securely and make sure they are complete.
  • Page 95 Spilled hydraulic oil must be set using a suitable agent and disposed of in accordance with environmental regulations. If hydraulic oil comes into contact with the skin, wash it off immediately with soap and water. If it comes into contact with the eyes rinse them immediately with flowing water and call for a doctor.

  • Page 96: Towing Trailers

    Towing trailers DANGER! Inappropriate speeds and excessive trailer loads can be dangerous If you do not adapt your speed and / or use an excessive trailer load, the truck can pull apart when cornering and braking. The truck should only be used occasionally to tow trailers. The overall weight of the trailer should not exceed the capacity indicated on the capacity plate, (see "Identification points and data plates"...
  • Page 97 Attaching the trailer CAUTION! Trapping hazard There is a trapping risk when you attach a trailer. Follow the instructions of the coupling manufacturer if using special trailer couplings. Secure the trailer to prevent it from rolling away before coupling it. Do not get caught between the truck and the tiller when coupling the trailer.

  • Page 98: Optional Equipment

    Optional equipment Steel cab For trucks fitted with a steel cabin, both doors can be closed. CAUTION! An open door can cause accidents (123) Do not travel with an open door (123). When opening the door make sure there is nobody in the door’s swing range.

  • Page 99: Sliding Windows

    Sliding windows CAUTION! An unlocked sliding window can cause accidents The sliding windows must be locked at all times. Opening and closing the windows Procedure • Push the lock (125) up. • Move the window forward or back. • Insert the lock in the stop (126).

  • Page 100: Panel Door

    Panel door CAUTION! An open door can cause accidents (123) Do not travel with an open door (123). When opening the door make sure there is nobody in the door’s swing range. Always close the door tightly and make sure it is locked. Closing the door does not release the driver from his responsibility to wear a seat belt, (see "Seat Belt"...

  • Page 101: Backrest Extension

    Backrest extension CAUTION! Accident risk when adjusting the backrest during travel The backrest extension must not be changed during travel! Procedure • The backrest extension height can be adjusted by changing the detent. • To do this push the backrest up or down.

  • Page 102: Heating And Air Conditioning System

    Heating and air conditioning system 6.6.1 Heating Heating operation Procedure • Turn the thermostat control button (129) anti-clockwise to increase the temperature in the driver’s cab. • Press the switch (128) to switch on the fan. 6.6.2 Air conditioning system CAUTION! Extreme temperature differences can affect your health.
  • Page 103 Power On and Off Procedure • Turn on the fan switch (128) and press the toggle switch (130) (green indicator goes on) • Airflow control with discharge jets (131). Using the air conditioning system at high air humidity and temperature levels Procedure •...

  • Page 104: Removable Load Backrest

    Removable load backrest CAUTION! Trapping hazard and heavy load backrest weight Wear safety gloves and safety shoes when carrying out this operation. Two people are required to remove and attach the load backrest. Load backrest disassembly Procedure • Loosen the screws (132) •...

  • Page 105: Rockinger Coupling With Hand Lever Or Remote Control

    Rockinger coupling with hand lever or remote control Refer to the instructions for towing trailers, (see "Towing trailers" on page 96). CAUTION! Incorrectly coupled trailers can cause accidents Make sure the coupling is engaged securely before starting the truck. The contro pin (136) must be flush with the control sleeve (137).

  • Page 106: Camera System

    6.10 Camera system CAUTION! Accident risk from hidden work areas The camera system acts as an aid to assist safe operation. Practice travelling and working with the camera system. Align the camera so that the hidden work area can be seen. When using the camera to reverse, the monitor automatically switches on when you engage reverse gear.

  • Page 107: Optional Equipment For Working In Areas With Heavy Accumulation Of Dust

    6.11 Optional equipment for working in areas with heavy accumulation of dust When working in areas with high levels of dust (lint, splinters) the Industrial truck can be fitted with an optional lint filter on the cooler. CAUTION! Clogged lint filters can cause fires The lint filter must be cleaned regularly according to how much it is clogged.

  • Page 108: Tilt Angle Display

    6.13 Tilt angle display NOTE The current tilt angle is shown in an additional display that is attached on the right of the dashboard. – Green LEDs (146) indicate the vertical position to the ground. 6.14 Speed reduction The maximal achievable speed is limited to a preset value. Full motor speed and power are available while stopped and accelerating.

  • Page 109: Temperature Control System

    6.17 Temperature control system WARNING! In each case the cause of the overheating must be established and rectified by a trained and authorised customer service engineer. The warning indicator (94) goes on and an audible warning is sounded when the permissible coolant temperature...

  • Page 110: Troubleshooting

    Troubleshooting Troubleshooting This chapter enables the user to identify and rectify basic faults and the effects of incorrect operation. When trying to locate a fault, proceed in the order shown in the table. If the industrial truck cannot be restored to operational status after carrying out the following remedial operations, contact the manufacturer’s service department.
  • Page 111 Fault Possible Cause Action Starter does Travel direction switch Set the travel direction switch to neutral. not turn not in neutral Battery charge too low Check battery charge, charge battery if necessary Battery terminal cable Clean and grease terminals, tighten battery loose or terminals terminal cable oxidized.
  • Page 112 Fault Possible Cause Action Engine Engine oil level too low Check engine oil level, top up if necessary temperature Radiator contaminated Clean radiator display in red Coolant level too low Check engine radiator system for leaks, add zone coolant if necessary Fan V belt slipping Check V belt tension, tighten or replace as required...

  • Page 113: Operating The Truck Without Its Own Drive System

    Operating the truck without its own drive system 7.2.1 Towing the truck WARNING! Accident risk Other people can be injured if the truck is towed incorrectly. Only use vehicles to tow the truck which have sufficient tow and brake forces for the trailer load without its own braking system.
  • Page 114 7.2.2 Emergency lowering The mast can be lowered manually if a fault occurs in the hydraulic system. WARNING! Lowering the mast can result in injuries Instruct other people to move out of the hazardous area of the truck during emergency lowering. Never stand underneath a raised load handler.
  • Page 115 7.2.3 Starting aid WARNING! Danger from overheating Only use an ISO 6722 battery jump lead with fully insulated terminal pliers and a lead diameter of at least 25 mm The jump start connection (152) is located in the main fuse box on the starter battery. Procedure •...

  • Page 117: F Industrial Truck Maintenance

    F Industrial Truck Maintenance Operational Safety and Environmental Protection The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists. WARNING! Risk of accidents and damage to components Any modification to the truck, in particular the safety mechanisms, is prohibited.

  • Page 118: Maintenance Safety Regulations

    Maintenance Safety Regulations Maintenance and repair personnel Truck maintenance and repair work must only be carried out by specially trained personnel. A maintenance contract with the manufacturer will ensure trouble-free operation. The manufacturer’s service department has customer service technicians specially trained for these tasks. Lifting and jacking up WARNING! Lifting and jacking up the truck safely...
  • Page 119 Cleaning CAUTION! Fire hazard The truck must not be cleaned with flammable fluids. If flammable materials are not removed from the engine compartment, they can come into contact with hot components and cause a fire. Carry out all necessary safety measures to prevent sparking before cleaning (e.g. by short-circuiting).
  • Page 120 Electrical system CAUTION! Accident risk from Electrical system: Only trained personnel may work on the electrical system. Before working on the electrical system, all precautionary measures must be taken to avoid electrical accidents. The connecting leads on the starter battery must be disassembled to disable it. WARNING! Electric currents can cause accidents Make sure the electrical system is voltage-free before starting work on it.
  • Page 121 Tyre type WARNING! The use of tyres that do not match the manufacturer's specifications can result in accidents. The quality of tyres affects the stability and performance of the truck. Uneven wear affects the truck's stability and increases the stopping distance. When replacing tyres make sure the truck is not skewed.
  • Page 122 Hydraulic hoses WARNING! Brittle hydraulic hose lines can cause accidents The hoses must be replaced every six years. The manufacturer's customer service department is specially trained to carry out these operations. WARNING! Hydraulic line leaks can cause accidents Hydraulic oil can escape from leaky and faulty hydraulic lines. Report any defects immediately to your supervisor.

  • Page 123: Servicing And Inspection

    The application conditions of an industrial truck have a considerable impact on the wear of the service components. We recommend that a Jungheinrich customer service adviser carries out an application analysis on site to work out specific service intervals to prevent damage due to wear.
  • Page 124 Electrical System W A B C Test displays and controls. Test warning and safety devices in accordance with operating instructions. Test panel switch and check for damage. Power Supply W A B C Check battery and battery components. Check battery cable connections are secure, grease terminals if necessary.
  • Page 125 Heating Chassis and superstructure W A B C Test heating. Clamping device Hydraulic operations W A B C Attachment: Clean and lubricate. Sideshifter Hydraulic operations W A B C Attachment: Clean and lubricate. Road traffic approval (StVZO) Electrical System W A B C Test lighting.
  • Page 126 Optional equipment Chassis and superstructure W A B C Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage.

  • Page 127: Customer Service

    Customer Service 4.2.1 Standard equipment Brakes W A B C Test brakes. Check brake lining. Check brake fluid level in the compensation tank and top up if necessary. Check connections and lines for leaks. Check brake mechanism, adjust and lubricate if necessary. Note: Replace brake fluid after 2000 service hours or every two years.
  • Page 128 Travel W A B C Check wheel suspension and attachment. Check wheels for wear and damage. Check tyre air pressure and top up if necessary. Replace transmission oil. Check maximum speed of the motor without load, adjust if necessary. Test water pump and the fans. Test starter and generator, Check wires and attachment.
  • Page 129 Hydraulic operations W A B C Check settings and wear levels of slide pieces and stops and adjust the slide pieces if necessary. Visually inspect the mast rollers and check contact surface wear level. Check lateral clearance of the mast connections and the fork carriage.
  • Page 130 Steering W A B C Check steering axle and steering knuckle for wear and damage. Check steering hoses and lines. Check stub axle and adjust if necessary. Test hydraulic steering for leaks. Grease the steering axle. 4.2.2 Optional equipment Discharge strap Electrical System W A B C Check anti-static discharge strap is present and not damaged.
  • Page 131 Electrical optional equipment Electrical System W A B C Test electrical optional equipment and check for damage. Overhead guard cover Chassis and superstructure W A B C Check overhead guard cover is present, check for damage and make sure it is secure. Fire extinguisher Agreed performance levels W A B C...
  • Page 132 Air conditioning system Chassis and superstructure W A B C Note: The air conditioning system must only be serviced every two years or 2000 service hours by specialist personnel. Test air conditioning system and its settings and check its components for damage. Check temperature reading at the outlet of the ventilation nozzles against manufacturer's ratings.
  • Page 133 Impact sensor Electrical System W A B C Check impact sensor is secure and check for damage. Sideshifter Hydraulic operations W A B C Check attachment is properly secured to the truck and the supporting elements. Test hose reel and check for leaks and damage. Attachment: check bearing points, guides and stops for wear and damage, grease and clean these components.
  • Page 134 Hydraulic operations W A B C Test operation and setting of the attachment. Check attachment for damage. Check piston and piston rod for damage, check setting and adjust if necessary. Check that hydraulic ports, hose and pipe lines are secure, check for leaks and damage.

  • Page 135: Maintenance Checklist Tfg

    Fork positioner Hydraulic operations W A B C Check attachment is properly secured to the truck and the supporting elements. Test hose reel and check for leaks and damage. Attachment: check bearing points, guides and stops for wear and damage, grease and clean these components.
  • Page 136 Electrical System W A B C Test displays and controls. Test warning and safety devices in accordance with operating instructions. Test panel switch and check for damage. Power Supply W A B C Check battery and battery components. Check battery cable connections are secure, grease terminals if necessary.
  • Page 137 Heating Chassis and superstructure W A B C Test heating. Clamping device Hydraulic operations W A B C Attachment: Clean and lubricate. Sideshifter Hydraulic operations W A B C Attachment: Clean and lubricate. Road traffic approval (StVZO) Electrical System W A B C Test lighting.
  • Page 138 Optional equipment Chassis and superstructure W A B C Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage.

  • Page 139: Customer Service

    Customer Service 5.2.1 Standard equipment Brakes W A B C Test brakes. Check brake lining. Check brake fluid level in the compensation tank and top up if necessary. Check connections and lines for leaks. Check brake mechanism, adjust and lubricate if necessary. Note: Replace brake fluid after 2000 service hours or every two years.
  • Page 140 Travel W A B C Test anti-freeze, top up if necessary. Check engine suspension. Check transmission for noise and leakage. Check transmission oil level or grease filling of the transmission and top up if necessary. Check wheel suspension and attachment. Check wheels for wear and damage.
  • Page 141 Chassis and superstructure W A B C Check chassis and screw connections for damage. Check trailer coupling or tow mechanism stop. Check attachment and setting function of the driver's seat. Check operator mat and steps are non-slip and damage-free. Check engine compartment for contamination and clean if necessary.
  • Page 142 Steering W A B C Test hydraulic steering and its components. Check mechanical parts of steering column. Check steering axle and steering knuckle for wear and damage. Check steering hoses and lines. Check stub axle and adjust if necessary. Test hydraulic steering for leaks. Grease the steering axle.
  • Page 143 Electrical optional equipment Electrical System W A B C Test electrical optional equipment and check for damage. Overhead guard cover Chassis and superstructure W A B C Check overhead guard cover is present, check for damage and make sure it is secure. Fire extinguisher Agreed performance levels W A B C...
  • Page 144 Air conditioning system Chassis and superstructure W A B C Note: The air conditioning system must only be serviced every two years or 2000 service hours by specialist personnel. Test air conditioning system and its settings and check its components for damage. Check temperature reading at the outlet of the ventilation nozzles against manufacturer's ratings.
  • Page 145 Sideshifter Hydraulic operations W A B C Check attachment is properly secured to the truck and the supporting elements. Test hose reel and check for leaks and damage. Attachment: check bearing points, guides and stops for wear and damage, grease and clean these components. Check cylinder piston rods and bushings.
  • Page 146 Hydraulic operations W A B C Test operation and setting of the attachment. Check attachment for damage. Check piston and piston rod for damage, check setting and adjust if necessary. Check that hydraulic ports, hose and pipe lines are secure, check for leaks and damage.
  • Page 147 Fork positioner Hydraulic operations W A B C Check attachment is properly secured to the truck and the supporting elements. Test hose reel and check for leaks and damage. Attachment: check bearing points, guides and stops for wear and damage, grease and clean these components.

  • Page 148: Lubricants And Lubrication Schedule

    Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. Keep consumables away from hot components and naked flames. Always keep consumables in prescribed containers.
  • Page 149 Consumables and used parts CAUTION! Consumables and used parts are an environmental hazard Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. To change the oil contact the manufacturer's customer service department, who have been specially trained for this task. Note the safety regulations when handling these materials.

  • Page 150: Lubrication Schedule

    Lubrication Schedule TFG DFG Contact surfaces Transmission oil filler neck Grease nipple Transmission oil drain plug Brake fluid filler neck for brake Hydraulic oil filler neck system Hydraulic oil drain plug Ö Engine oil filler neck...

  • Page 151: Consumables

    Consumables DFG/TFG 316/320 Code Order no. Packag Capacity Component Used for quantit 51132827 55 l Jungheinrich Hydraulic hydraulic oil system 00002832 0.25 l Brake fluid SAE J Brake system 1703 50055726 K-P-2K grease 29201280 400 ml Chain spray Mast chains 05099205 5.4 l...
  • Page 152 WARNING! Using incorrect hydraulic oil can be dangerous Do not use hydraulic oils with a different specification or viscosity and do not mix with additives. Grease guidelines Code Saponification Dew point Worked penetr. at NLG1 class Application °C 25°C temperature °C Lithium 265-295 -35/+120...
  • Page 153 Coolant specification The quality of the coolant used can have a major impact on the efficiency and service life of the cooling circuit. The recommendations listed below are useful for servicing a good cooling circuit with anti-freeze and/or anti-corrosion. Always use clean, soft water. Do not use distilled water. DANGER! Anti-freeze is poisonous Anti-freeze contains ethylene glycol and other components which can result in...

  • Page 154: Maintenance And Repairs

    Maintenance and repairs Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: Procedure • Park the truck securely, (see "Parking the truck securely"...

  • Page 155: Unlocking The Engine Bonnet

    Unlocking the engine bonnet Unlocking the engine bonnet Requirements – For trucks with a closed cab open both cabin doors before lifting the engine cover (o). Procedure • Unlock the steering column with the steering column adjustment lever (154) and push it forward fully.

  • Page 156: Checking The Wheel Attachments

    Checking the wheel attachments. WARNING! Using different tyres can cause accidents The quality of tyres affects the stability and performance of the truck. The diameter of the wheels must differ by no more than 15 mm. Always replace tyres in pairs. After replacing the tyres check the wheel nuts are secure after 10 service hours.

  • Page 157: Hydraulic System

    Hydraulic system CAUTION! The hydraulic oil is pressurised during operation and is a hazard to health and to the environment. Do not touch pressurised hydraulic lines. Dispose of used oil in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations.
  • Page 158 7.5.1 Checking the hydraulic oil level Requirements – Park the truck on a level surface. – Start the engine and fully raise and lower the mast once. – Switch off the engine. Procedure • Remove the hydraulic oil dipstick (157) from the hole wipe it with a clean cloth and insert it fully again.
  • Page 159 7.5.3 Replacing the hydraulic oil filter Procedure • Loosen the quick release on the strap retainer of the air filter and push the air filter housing to the side. • Unscrew the lid (158). • Remove the hydraulic oil filter in the lid.

  • Page 160: Engine Maintenance

    Engine maintenance DANGER! A running engine can be dangerous. There is a high risk of injury when the cover is open and the engine running. Do not reach into moving parts (e.g. fan, belt drive). Truck maintenance and repair work must only be carried out by specially trained personnel who have been authorised by the owner.
  • Page 161 7.6.2 DFG engine maintenance NOTE Used oil contaminates the environment Dispose of used oil and used engine oil filters in accordance with environmental regulations. CAUTION! Risk of scalding through hot oil. Wear appropriate safety gloves when replacing the oil and oil filter. NOTE When the engine is cold the engine oil can be viscous.
  • Page 162 Draining the engine oil Procedure • Remove the floorboard. • Unscrew the filler cap (164). • Thoroughly clean the oil drain plug (165) and around the drain hole. • Unscrew the oil drain plug. • Collect any oil that emerges. •...
  • Page 163 Adding engine oil Procedure • Add fresh engine oil through the filler port (164) in accordance with the consumables table. • Check the engine oil level with the dipstick (163) and top up if necessary, (see "Consumables" on page 151). •...
  • Page 164 7.6.3 Replacing the fuel filter NOTE Fuel cause environmental damage Bind any spilled diesel fuel with suitable means. Then dispose of the diesel and fuel filter accordance with environmental regulations. Procedure • Drain the fuel from the filter into a suitable container.
  • Page 165 7.6.5 Check V-belt for damage NOTE A damaged V-belt will result in malfunctions. If the V-belt is not in a suitable condition, you must only start to use the truck when the damage has been rectified. Procedure • Check the V-belt for cracks, deformation and wear. 7.6.6 Checking the V belt tension Procedure •...
  • Page 166 7.6.8 TFG engine maintenance NOTE Used oil contaminates the environment Dispose of used oil and used engine oil filters in accordance with environmental regulations. CAUTION! Risk of scalding through hot oil. Wear appropriate safety gloves when replacing the oil and oil filter. NOTE When the engine is cold the engine oil can be viscous.
  • Page 167 Draining the engine oil Procedure • Remove the floorboard. • Unscrew the filler cap (164). • Thoroughly clean the oil drain plug (165) and around the drain hole. • Unscrew the oil drain plug. • Collect any oil that emerges. •...
  • Page 168 NOTE The incorrect amount of oil will damage the engine. After replacing the oil and oil filter carry out a test run and check the oil pressure display (82). Check that the oil drain plug and oil filter housing are tight. 7.6.9 Replacing spark plugs Procedure •...
  • Page 169 7.6.10 Check V-belt for damage NOTE A damaged V-belt will result in malfunctions. If the V-belt is not in a suitable condition, you must only start to use the truck when the damage has been rectified. Procedure • Check the V-belt for cracks, deformation and wear. 7.6.11 Checking the V belt tension Procedure •...
  • Page 170 7.6.13 Cooling system NOTE Lack of coolant can cause malfunctions The coolant level should be between the “MIN” and “MAX” markings on the expansion vessel. If the coolant is below the MIN marking, this indicates possible leakage in the radiator system. Do not continue using the truck.
  • Page 171 Check the coolant concentrate Tools and Material Required – Anti-freeze tester for coolants Procedure • Slowly unscrew the filler cap (174) from the expansion vessel (172). • Check the anti-freeze content of the coolant with an anti-freeze tester. NOTE The incorrect coolant concentration can cause malfunctions If there is insufficient anti-freeze content arrange for trained personnel to restore...
  • Page 172 7.6.14 Replace air filter cartridge DANGER! A running engine can be dangerous Carry out all maintenance work with the engine switched off. Do not start the engine if the air filter cartridge is removed. Replace air filter cartridge Procedure • Undo the 2 mounting clamps (180) and remove the dust collector pot.

  • Page 173: Checking Electrical Fuses

    Checking electrical fuses Checking electrical fuses Requirements – Prepare the truck for maintenance and repairs ((see "Preparing the truck for maintenance and repairs" on page 154)). Procedure • Open the rear cover of the truck, (see "Opening the rear panel" on page 154). •...
  • Page 174 7.7.1 Fuse ratings Standard fuse box (DFG) Item Description Electric circuit Rating (A) t Pre-heat relay, diesel valve t Air filter control, travel direction valves, seat switch, horn t Diesel filter control, brake fluid control, handbrake control t Display unit t 12-volt system t Ignition on options relay Standard fuse box (TFG)
  • Page 175 Fuses DFG main current Item Description Electric circuit Rating (A) t Preheat fuse 9F11 o Engine running option relay o Ignition on options relay t Key switch 9F16 t Pre-fuse for F19 9F17 t 50 A generator 9F19 t 80 A generator t 120 A generator TFG main current Item...
  • Page 176 Road traffic system fuse box Item Description Electric circuit Rating (A) o Lighting control fuse II 5F5.1 DFG options fuse box Item Description Electric circuit Rating (A) o Heating fuse o Seat heating control fuse o Speed signal generator fuse 9F21 o Soot filter electronics control fuse TFG options fuse box...

  • Page 177: Starter Battery

    Starter battery Checking the battery condition, acid level* and acid density* *not for maintenance-free batteries CAUTION! Battery acid can be dangerous Battery acid is highly corrosive. Therefore it is essential to avoid contact with battery acid. If clothing, skin or eyes have nevertheless come into contact with battery acid, immediately rinse the affected parts with water.

  • Page 178: Exhaust System

    Exhaust system Check the exhaust system regularly for leaks. Procedure • Open the engine cover. • Start the engine when the engine cover is open, (see "Starting the engine with the cover open" on page 160) • Check for any rising smell of exhaust and changed engine noise level. In this case the truck must be examined by specialist personnel.

  • Page 179: Seat Belt Maintenance

    7.10 Seat belt maintenance Check the safety restraint belt Procedure • Pull out the belt completely and check for fraying • Test the belt buckle and make sure the belt returns correctly into the retractor. • Check the cover for damage. Testing the automatic blocking system Procedure •...

  • Page 180: Brake

    The parking brake (73) must be able to hold the truck plus the maximum load on an incline of 15%. If it cannot, the parking brake must be adjusted. Please contact Jungheinrich customer services in this case. 7.12.2 Checking the brake fluid level Procedure •...

  • Page 181: Restoring The Truck To Service After Maintenance And Repairs

    7.13 Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck. • Lubricate the truck according to the lubrication schedule, (see "Lubrication Schedule" on page 150). • Clean the battery, grease the terminals and connect the battery. •...

  • Page 182: Decommissioning The Industrial Truck

    Decommissioning the industrial truck If the truck is to be out of service for more than a month, e.g. for commercial reasons, it must be stored in a frost-free and dry room. All necessary measures must be taken before, during and after decommissioning as described hereafter. WARNING! Lifting and jacking up the truck safely In order to raise the truck, the lifting gear must only be secured to the points specially...

  • Page 183: Prior To Decommissioning

    Prior to decommissioning Procedure • Thoroughly clean the truck. • Test the brakes. • Check the hydraulic oil level and replenish if necessary, (see "Checking the hydraulic oil level" on page 158). • Apply a thin layer of oil or grease to any non-painted mechanical components. •...

  • Page 184: Restoring The Truck To Service After Decommissioning

    Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck. • Lubricate the truck according to the lubrication schedule, (see "Lubrication Schedule" on page 150). • Clean the battery, grease the terminals and connect the battery. • Charge the battery, (see "Starter battery" on page 177). •...

  • Page 185: Safety Tests To Be Performed At Intervals And After Unusual Incidents

    Perform a safety check in accordance with national regulations. Jungheinrich recommends the truck be checked to FEM guideline 4.004. The Jungheinrich safety department has trained personnel who are able to carry out inspections. The truck must be inspected at least annually or after any unusual event by a qualified inspector (be sure to comply with national regulations).

  • Page 186: Final De-Commissioning, Disposal

    Final de-commissioning, disposal Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed. The truck must only be disassembled by trained personnel in accordance with the procedures as specified by the manufacturer.

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